Discipline: Technology and Engineering
Raquael Ballard - Virginia State University
Co-Author(s): Michael Lewis, Virginia State University, Petersburg VA
Statistical Gage Repeatability and Reproducibility studies are conducted on commercial injection molded automotive components utilizing instruments of different accuracy and precision; including manual height indicator, Keyence digital confocal microscope, Wenzel coordinate measuring machine CMM and Hitachi scanning electron microscope SEM. The results indicate that the CMM has the most capability for metrology in a manufacturing environment but the digital microscope and the manual height indicator can yield comparable results quickly. The SEM has the highest scientific accuracy and can be used when high resolution is needed to justify the added expense. The effect of varying the dimensions of the metal molds is correlated to the metrology of the plastic components. The same plastic components are replicated using a Stratasys 3D Printer and when compared dimensionally with the injection molded parts, they can meet the specifications, depending upon the fabrication materials and processing conditions. Future advanced components are also fabricated using Solid Works CAD Computer Aided Design software and the Stratasys 3D printer, illustrating a major advantage of additive manufacturing: virtual new designs can be digitally manipulated to meet the specifications and then printed without the need for an expensive and time consuming metal mold.
Funder Acknowledgement(s): NSF
Faculty Advisor: S. Akbar, Sakba@vsu.edu
Role: Collected data, analysis of data